Power Electronics, Machines and Control Research Group

European Research Activities in Aerospace

Prof Pat Wheeler

Email. Pat.wheeler@nottingham.ac.ukTel. +44 7963 290871

Introduction• Profile the PEMC Research Group

– Power Electronics and machines research– Facilities' and funding– Aerospace Research: the More Electric Aircraft

• The Route to EC Projects– Getting known: EEDAS [DTI Funding]– Getting involved: POA [Dissemination Event]– Getting organised: MOET [EC Funding] – Longer term: Clean Sky JTI [EC Funding]– Infrastructure: [ERDF Funding]

• Lessons Learnt– SME interaction example - Dynex

PEMC Research Team9 Academic Staff [Faculty]• Prof Jon Clare (Power Electronics) – Head of Group• Prof Greg Asher (Drives, Control)• Prof Mark Johnson (Power Device Technologies, Energy)• Prof Pat Wheeler (Power Electronics)• Dr Mark Sumner (Drives, Power Quality, Energy)• Dr Christian Klumpner (Power Electronics)• Dr Pericle Zanchetta (Control, Power Quality)• Dr Chris Gerada (Machines, Drives)• Dr Alberto Castleazzi (Power Device Technologies) ≈ 85 Researchers• ≈ 40 Post Doctoral Research Fellows

• ≈ 45 PhD students

Current Research Grants Active ≈ £18M

Research Council29%

European Commission

33%

Knowledge Transfer Partnerships

15%Industry

16%TSB/Industry

4%

Overseas Industry4%

Faculty of EngineeringElectrical and Electronic Engineering MechanicalMaterials and Manufacturing EngineeringGeorge Green Institute for ElectromagneticResearch Power ElectronicsMachines and Controls

Civil Engineering Chemical and Environmental EngineeringApplied Optics and Ultrasonics RF and PhotonicEngineering CFD & Heat Transfer

Research Areasl Power Electronicsl Advanced electrical actuation and machinesl Diagnostics and Prognosticsl Power Device Technology Packaging and Reliabilityl Electrical power systems

l 1500m2 of research laboratory− 1 MVA utility power supply− numerous experimental rigs 1kW-750kW and 3kV+− 270kVA electronic “aerospace” power supply

l Power converter research and development− Experimental work to 750kW− Construction up to 1MW− New materials and topologies

l Electrical machine research and development− NC wire EDM machine− Lamination cutting

l Electrical machine and drive testing to 800kW− Load, performance and functionality tests− Efficiency tests− 120,000rpm, 40kW dynamometer

l Calorimetric facilities− 37kW calorimeter for loss evaluation− Machines and impact of converters

l Environmental testing− Combined temperature, humidity, vibration, altitude− Rapid cycling (-70oC to +400oC)

l Power device packaging and characterisation − Prototyping: wire-bonding, vacuum reflow etc− Characterisation: electrical, thermal and reliability

PEMC Group – Facilities

Power Sources:“Conventional” AircraftJet Fuel

Propulsion Thrust (≈≈≈≈ 40MW)

Gearbox driven hydraulic pump

ElectricalGearbox driven

generatorsHydraulic

High pressure air “bled” from

enginePneumatic

Fuel pumps and oil pumps on

engineMechanical

200kW 1.2MW 240kW 100kW

Total “non-thrust” power ≈≈≈≈ 1.7MW

Figures for a typical A320/B737 size aircraft

“More Electric Aircraft” ConceptJet Fuel

Propulsion Thrust (≈≈≈≈ 40MW)

Electrical System power ≈≈≈≈ 1MW

Figures for a typical A320/B737 size aircraft

Expanded electrical networkEngine driven

generators

Existing electrical loads

New electrical loads• Rationalisation of power sources and networks• Bleedless engine technology

ELECTRICALFlight control actuationLanding gear/ Braking

Doors

ELECTRICALCabin pressurisation

Air conditioningIcing protection

ELECTRICALFuel pumping

Engine Ancillaries

Route to Involvement in EC Projects• Invitation to discuss possible project with Dowty,

Wolverhampton – initially a motor technology project– Dowty is now part of Moog

• DTI Funded project– EEDAS– 3 year project with 3 PhD students

• Road mapping event– with Electrical Systems NAC [part of KTN]– active participation

• Invitation to an EC project meeting in Paris– MOET planning meeting– Presentations and networking– Importance of WP leaders

EEDAS – DTI Funding

– Elimination of hydraulics• Electro-Mechanical Actuator• 30kW matrix converter • integrated with ballscrew housing/heatsink

– Holistic design of motor/load/power converter• Maximise system efficiency• Minimise system weight

– Advanced thermal management• Copes with intermittent operation

Example of an Actuation System Project

Matrix Converter

PMMotor Actuator

Control

Ram Position250Hz sampling rate2Hz bandwidth

Motor Current12.5kHz sampling rate200Hz Bandwidth

Motor Speed1.25kHz sampling rate20Hz bandwidth

Supply360Hz to800Hz

LVDTResolverLEMs

Supply Voltage

Ram Position Demand

Voltagetransducers Filter

European Project: MOETTOP-LEVEL OBJECTIVES:

Objective 1: Define and validate new electrical networks up to 1MW

Objective 2: Resolve and validate transformation of users into all electrical solutions

Objective 3: Develop and validate power electronics enabler technology

Objective 4: Integration into aircraft

Objective 5: Develop a coherent design environment to support PbW design & validation

TOP-LEVEL OBJECTIVES:

Objective 1: Define and validate new electrical networks up to 1MW

Objective 2: Resolve and validate transformation of users into all electrical solutions

Objective 3: Develop and validate power electronics enabler technology

Objective 4: Integration into aircraft

Objective 5: Develop a coherent design environment to support PbW design & validation

EXPECTED RESULTS

1 - Fuel burn: 2% less,

2 - Maintenance: 15$ cheaper per flight hour,

3 - Unexpected delays for systems: 50% less for power systems

4 - Power electronics weight reduction: 50% less

5 - System improvement: enhanced competitiveness, manufacturing improvement, technology validation & standard proposals

EXPECTED RESULTS

1 - Fuel burn: 2% less,

2 - Maintenance: 15$ cheaper per flight hour,

3 - Unexpected delays for systems: 50% less for power systems

4 - Power electronics weight reduction: 50% less

5 - System improvement: enhanced competitiveness, manufacturing improvement, technology validation & standard proposals

MOET – More Open Electrical Technologies

• 3.5-year, EC funded project • 63 partners and €67M

• July 2006 to December 2009

• MOET developed the POWER-BY-WIRE concept

• All applications reliant on power electronics

• Nottingham worked on many applications ofPower Electronics and modelling

PEPDC 230VAC

ECED6.21.1

NON Reversible Drive Rig

S/G1 S/G2 S/G3 NA

R 230V

R 540V

GCU GC U GCU GC U

Load

Fue lPum p

ECS

ECSLoad

EP

EMA

Reversible Drive Rig

A-F

Alim540VDC

PEPDC 115VACSA

D6.21.2

PEPDC 28VDCSA

D6.21.2

EMA

Load

Load

Active Filter

BATT

A-F

A-F

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A-F

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MCU2

THAD3.21 .1

THAD3.23.2

GOODD3.23.1

GOODD3.23.1

TFED3.22.3GOOD

D3.23.1THA

D3.23 .2

THAD4.31 .3

THAD4.31.2

A-F

THAD4.31.1

ARTUD6.22.1

ARTUD6.22.1

MOOGD4.31 .5

GAS-FD4.31 .6

MO ET – WP8

LARGE AIRCRAFT TEST BENCH

BASIC Architecture v02

2007

Sharp

SEPDU from WP6 to be connected: - SEPDU from CRZ (D6.21.3 ) : 115/230vac, +/-270vdc, 28vdc- SEPDU from SA (D6.21 .4) : 230vac, +/-270vdc, 28vdc

MOET – WP8 Large Aircraft BASIC Architecture

PUISS+

EP

A-F

SEPDUs

SAD6.21.4

CRZD6.21.3

3 3 3

3 3

3

3

3

R A-F

GAPCU GAPCU

PEPDC +/-270VDC

ECED6.21.1

Sta

rting

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ULTRAD4.31.4

WIPS LoadULTRAD4.31.4

ATUTHA

D3.21.1

TRUARTU

D6.22.2

3 33333

3

U-NAPD3.22.4

BATTARTU

D6.22.1

OR

ATRU1

ATRU2

3

Draft

Elec tronicModule

W IRING SUPPLIED by- W P8- W P6- THA- ULTRA- G AS-F

Test Rig

AIMEA - UK

© Copyright MOET Consortium 2006 10

• Academic Initiative for the More Electric Aircraft, UK• The Four Leading UK Universities in Electrical Aerospace Research

• ONE legal entity for the MOET project

• ‘AIMEA’ formed in December 2004• WP3 announced that it had contact four UK Universities

• Only room for one or two UK Universities in MOET

• Airbus said that AIMEA was an excellent idea• Reduced number of partners in MOET, involvement of all key UK academics

• All UK academic involvement in MOET was through AIMEA

AIMEAAIMEA --UK UK

The University of

Sheffield

The University of Manchester

Clean Sky JTI• Total project budget – €1.6B

– Duration – 7 years• Clean Sky JTI work is split into six “ITDs”• Led by 12 companies [Members]

– Thales, Liebherr, Airbus, Dassualt, Alenia, SAAB, Rolls Royce, Safran, EADS, ….

• Each ITD then has 5 or 6 other organisations [Associate Members]

• 25% of funding reserved for Calls for Proposals – See www.cleansky.eu now for calls and get

involved

l The University of Nottingham is an Associate member

• Systems for Green Operations ITD• We are the only University which is an Associate

Member in our own right• Total budget of about €10.3M

Clean Sky JTI

• Application process– Two pages of text – Letter of commitment to negotiate– Presentation at ‘open’ meeting in Brussels– Attending monthly meetings

• Importance of networking– Discussing options with WP leaders– Making other partners aware of our skills and activities– Inputting to documentation in a timely manner– Budget planning

JTI = Joint Technology Initiative“A JTI is a type of project created by the European Commission for funding

research in Europe to allow the implementation of ambitious and complex activities, including the validation of technologies at a high readiness level”

“The size and scale of JTIs requires the mobilisation and management of very substantial public and private investment and human resources”

Funding of the JTI• Distribution of Resources in the Clean Sky JTI

• The slit between ITD Leaders, Associates and Partners must be respected• Many Calls are undersubscribed at the moment

• Innovation is expect and required• Calls launched every 3 to 4 months• Keep checking the site

• Proposals judged on six criteria:• Technical excellence• Innovative character• Compliance with Specification

and timetable• Resources, management and

track record• Appropriate budget allocation• European competiveness

ERDF: Institute for Aerospace Technology • European Regional Development Funding [ERDF]

– Business engagement support: current research income about £35M– Matched funding from University and CIF: total £7.5M– Aerospace Research Centre :750 m2 for TRL 1-4 for PEMC Group– Aerospace Technology Centre: 1800m2 for TRL 4-6 for integrated

projects in Engineering Faculty

www.dynexsemi.com

About Dynex• Dynex designs and manufactures high power

semiconductor devices and assemblies, and silicon on sapphire (SOS) radiation hard ICs

• Dynex Semiconductor Ltd is the sole subsidiary of Dynex Power Inc.

• Semiconductor production started in Lincoln England in 1957

• 9,000m2 manufacturing & engineering facility

• ISO9001 & ISO14001• Prior trade names: AEI Semiconductors Ltd : AEI Marconi Electronic Devices Ltd: MEDL GEC-Plessey Semiconductors Ltd: GPS

Turnover

5

10

15

20

2005 2006 2007 2008

Sal

es £

mill

ion

Dynex: Products and Markets

� Power electronic assemblies• Design, build and refurbishment of high power

electronic assemblies.

� Power IGBT and diode modules to 3,600A & 6,500V• Specialising in the high voltage power market

� Power bipolar devices to 11,000A & 8,500V• Thyristors, GTOS and diodes for high-power

applications

� Customers are electronic equipment manufacturers and maintenance providers to the following sectors� Industrial:� Marine� Railway� Aerospace � Space satellites (SOS )

Dynex: Starting pointl First connection between Nottingham

and Dynex in 1990s• IEE Power Professional Group 6 Meeting

• Cork, Ireland• Importance of attending Networking events

• Jon Clare and Dinesh first met during the meeting• Start of regular informal links

l Informal links • Discussions on technology• Advice on applications – mutual benefit• Access to test facilities and equipment• Donation of components

l Funded projects• Letters of support • Donation of components• Collaboration in larger projects• Student projects…

2004 2008 2012

Knowledge

Transfer

Partnership

UNIFLEXUNIFLEXUNIFLEX

Clean Sky JTI?Clean Sky JTI?Clean Sky JTI?

DIPECDIPECDIPEC

Power Core?Power Core?Power Core?

MOETMOETMOET

IeMRC - ReliabuilityIeMRC IeMRC -- ReliabuilityReliabuility

EC Funded

Projects

UK Research

Projects

Dynex: Project TimelineFunded Collaborative Projects: Research Landscape Funded Collaborative Projects: Research Landscape University of Nottngham and DynexUniversity of Nottngham and Dynex

HIPPOSHIPPOSHIPPOS

Powe r ConvertersPowe r ConvertersPowe r Converters IGBT EvaluationIGBT EvaluationIGBT Evaluation

Thyristor TestingThyristor TestingThyristor Testing

PEATEPEATEPEATE

Integrated Matrix ConverterIntegrated Matrix ConverterIntegrated Matrix Converter

ASENTASENTASENT

SCEPTRESCEPTRESCEPTRE

IMPECTIMPECTIMPECT

IeMRC - PrognosticsIeMRC IeMRC -- PrognosticsPrognostics

2002

EPSRC

DTI/TSB

IeMRC

KTPs

Summary

• Nottingham has one of the largest research groups in Power Electronics and related technologies in the World

• Research spans:– Basic technology research (e.g. physics of failure)– Applied research (e.g. advanced technology demonstrators)– All involves working with industry

• European funding is one part of out research landscape– Networking– SME interaction– Application process